FORMULA SAE ENGINE INTERNALS GROUP Emerson Hawkins, Whitney Hurlbut, Kirk Fraser, Saad Mohamed and Greg Fitzpatrick
PRESENTATION OVERVIEW Plan FSAE Engine Internals Group Fall Presentation 2
PRESENTATION OVERVIEW Plan FSAE Engine Internals Group Fall Presentation 3
PRESENTATION OVERVIEW Plan Gearbox Crankshaft Flywheel FSAE Engine Internals Group Fall Presentation 4
PRESENTATION OVERVIEW Plan DAQ Vibration Rotational Mass FSAE Engine Internals Group Fall Presentation 5
PRESENTATION OVERVIEW Plan FSAE Engine Internals Group Fall Presentation 6
PRESENTATION OVERVIEW Plan FSAE Engine Internals Group Fall Presentation 7
PRESENTATION OVERVIEW Plan FSAE Engine Internals Group Fall Presentation 8
PROJECT OVERVIEW AND OUTCOMES Formula SAE Students develop and market a low-production, open-wheeled racecar for weekend autocross racers Overview and Plan FSAE Engine Internals Group Fall Presentation 9
PROJECT OVERVIEW AND OUTCOMES Honda CBR 600RR Engine with a 20 mm intake restriction: Power: 70.5 bhp @ 9500 RPM Torque: 53.7 Nm @ 9000 RPM Top speed: 140 km/h Overview and Plan FSAE Engine Internals Group Fall Presentation 10
Output Torque (Nm) Output Torque (Nm) PROJECT OVERVIEW AND OUTCOMES 350 Torque Curve for Stock Gearbox Ratios Torque Curve for Modified Racing Gearbox Ratios 350 300 300 250 200 150 100 250 200 150 100 Gear 1 Gear 2 Gear 3 Gear 4 Gear 5 Gear 6 50 50 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Vehicle Speed (km/h) 0 0 10 20 30 40 50 60 70 80 90 100 110 120 Vehicle Speed (km/h) Overview and Plan FSAE Engine Internals Group Fall Presentation 11
PROJECT OVERVIEW AND OUTCOMES Reduce rotating mass Gearbox Main Shaft Counter Shaft Crankshaft Flywheel Overview and [USA, Motorcycle USA.2005 BMW K1200S Photo Gallery. n.d. http://www.motorcycle-usa.com] Plan FSAE Engine Internals Group Fall Presentation 12
PROJECT OVERVIEW AND OUTCOMES Improve Overall Performance Acceleration Torque Power Throttle Response Weight Reduction Drivability Overview and Plan FSAE Engine Internals Group Fall Presentation 13
DESIGN REQUIREMENTS Increase torque by 5% from baseline of 53.7 Nm. Increase overall horsepower by 5% from baseline of 70.5 hp. Increase throttle response by 10% from baseline of 0.427 seconds. Decrease 75m acceleration time by 5% from baseline of 4.797s. Decrease internal rotating mass by 5% from baseline of 17.5 kg Plan FSAE Engine Internals Group Fall Presentation 14
Overall Placing PROJECT OVERVIEW AND OUTCOMES Historical and Predicated Placing 0 Competition Year 2010 2011 2012 2013 2014 10 20 30 31st 40 40th 50 60 58th 70 80 77th 90 93rd 100 Plan FSAE Engine Internals Group Fall Presentation 15
Total Points PROJECT OVERVIEW AND OUTCOMES 500 Historical and Predicted Point Distribution 450 400 350 300 250 200 150 100 Efficiency Endurance Autocross Skid Pad Acceleration Presentation Cost 50 0 2010 2011 2012 2013 2014 Competition Year Plan FSAE Engine Internals Group Fall Presentation 16
DESIGN ALTERNATIVES Gearbox Alternatives: 1) a Custom Gearbox a) Build it b) Outsource it 2) Modify the Nova Racing Honda CBR 600RR Racing Gearbox a) 6 speed b) 5 speed c) 4 speed 3) Modify the Stock Honda CBR 600RR Gearbox a) 5 speed b) 4 speed Gearbox Crankshaft Flywheel Plan FSAE Engine Internals Group Fall Presentation 17
DESIGN ALTERNATIVES Gearbox Crankshaft Flywheel Plan FSAE Engine Internals Group Fall Presentation 18
DESIGN ALTERNATIVES Crankshaft Alternatives: 1) Reduce overall mass a) Drill holes throughout b) Reduce outer diameter of lobes c) Reduce thickness of the lobes Gearbox Crankshaft Flywheel Plan FSAE Engine Internals Group Fall Presentation 19
DESIGN ALTERNATIVES Flywheel Alternatives: 1) Machine Outer Radius to Reduce Weight 2) Total-Loss System Gearbox Crankshaft Flywheel Plan FSAE Engine Internals Group Fall Presentation 20
ENGINEERING ANALYSIS Testing and Data 1. Mass and Dimensions 2. Simulations 3. Dynamometer 4. Test Driving DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 21
ENGINEERING ANALYSIS Mass Distribution of Rotating Engine Components Counter Shaft 19% Forks R 1% Shift Drum 3% Flywheel 7% Main Shaft 10% Steel Discs 4% Clutch Center 3% Clutch 1% Crankshaft 38% IN Cam EX Cam 6% Piston 6% 2% DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 22
ENGINEERING ANALYSIS Other 44% Main Shaft Gears (% of shaft) Fifth 13% Third/ Fourth 21% Other 37% Counter Shaft Gears (% of shaft assembly) First 11% Fifth 15% Fourth 6% Second 8% Sixth 14% Second 9% Sixth 15% Third 7% DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 23
ENGINEERING ANALYSIS Component Dimensions DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 24
ENGINEERING ANALYSIS Simulations Optimum Lap Load Vehicle Graph Engaged Gears Lap Times www.optimumg.com DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 25
ENGINEERING ANALYSIS Optimum Lap Dal FSAE DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 26
ENGINEERING ANALYSIS Engine Dynamometer Baseline Engine Performance Curves HP Torque DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 27
ENGINEERING ANALYSIS Dynamic Testing Acceleration runs Stop watch Static Testing Throttle Response MoTeC i2 Standard DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 28
ENGINEERING ANALYSIS Gear Stock Ratio % Drop Nova Racing % Drop 1 2.666:1 2.666:1 2 1.938:1 27.3% 2.133:1 20.0% 3 1.611:1 16.8% 1.833:1 14.0% 4 1.409:1 12.5% 1.631:1 11.0% 5 1.260:1 10.6% - - 6 1.166:1 7.5% - - Overall Reduction Gear Ratios 2.286:1 56.3% 1.635:1 38.8% DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 29
ENGINEERING ANALYSIS Heavy rotating mass slow acceleration Light rotating mass more horsepower DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 30
ENGINEERING ANALYSIS Moment of Inertia: Stores kinetic energy Resists engine rotation Slows acceleration and throttle response Equivalent Mass: Relates rotating mass to static mass on car DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 31
ENGINEERING ANALYSIS Power : Dependant on engine RPM Smaller MOI requires less power for acceleration Smaller power requirement = faster acceleration DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 32
ENGINEERING ANALYSIS Original parameters Crankshaft Flywheel Mass 8.31 kg 1.51 kg MOI 9.12E-2 kgm 2 3.856E-2 kgm 2 Equivalent mass 33.26 kg 9.48 kg Rotational Power req. 1611.05 W 681.01 W After modifications Crankshaft Flywheel Mass Reduction 3.3% 10.7% MOI reduction 9.7% 16.4% Equivalent mass reduction 3.3% 10.7% Power req. decrease 9.7% 16.4% DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 33
ENGINEERING ANALYSIS Vibration: Engine is constantly operating at high speed reciprocating motion. Vibration is inevitable. Minimizing vibration improves drivability. Crankshaft and Flywheel requires careful machining. DAQ Rot. Mass Vibration Plan FSAE Engine Internals Group Fall Presentation 34
PROPOSED DESIGN Flywheel Total Loss System Reduce outer diameter Crankshaft Drill holes Knife edge lobes Reduce counterweight radius Gearbox and build custom Stock Honda, gears 5 & 6 removed Nova Racing, gears 5 & 6 removed Plan FSAE Engine Internals Group Fall Presentation 35
BUDGET Item Description: Quantity: Cost: Total (CAD): Nova Racing CBR 600RR Racing Gearbox 1 550.00 $ 918.50 Nova Automotive Crank Balancing 1 $ 150.00 $ 150.00 Donated Royal Purple Oil 4 $ 50.40 $ - Machine Crankshaft at Dalhousie 1 $ - $ - Machine Flywheel at Dalhousie 1 $ - $ - Safety Supplies (Cones and Caution Tape) 1 $ 149.68 $ 149.68 Gasket Maker 1 $ 29.99 $ 29.99 Assembly Lube 1 $ 16.19 $ 16.19 Fasteners 8 $ 62.56 $ 62.56 Total (CAD): $ 1,326.92 Plan FSAE Engine Internals Group Fall Presentation 36
PROJECT PLAN Plan FSAE Engine Internals Group Fall Presentation 37
THANK YOU FOR YOUR TIME. QUESTIONS? https://blogs.dal.ca/formulasae/